Staple cartridge comprising cartridge body and attached support

ABSTRACT

A surgical severing and stapling instrument, suitable for laparoscopic and endoscopic clinical procedures, clamps tissue within an end effector of an elongate channel pivotally opposed by an anvil. An E-beam firing bar moves distally through the clamped end effector to sever tissue and to drive staples on each side of the cut. The E-beam firing bar affirmatively spaces the anvil from the elongate channel to assure properly formed closed staples, especially when an amount of tissue is clamped that is inadequate to space the end effector. In particular, an upper pin of the firing bar longitudinally moves through an anvil slot and a channel slot is captured between a lower cap and a middle pin of the firing bar to assure a minimum spacing. Forming the E-beam from a thickened distal portion and a thinned proximal strip enhances manufacturability and facilitates use in such articulating surgical instruments.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 16/384,011, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Apr. 15, 2019, now U.S. Patent Application Publication No. 2019/0307452, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 15/679,300, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Aug. 17, 2017, which issued on May 21, 2019 as U.S. Pat. No. 10,292,707, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/850,030, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Sep. 10, 2015, which issued on Aug. 22, 2017 as U.S. Pat. No. 9,737,303, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/521,748, entitled STAPLE CARTRIDGE, filed Oct. 23, 2014, which issued on Dec. 6, 2016 as U.S. Pat. No. 9,510,830, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/175,148, entitled SURGICAL STAPLING INSTRUMENT, filed Feb. 7, 2014, which issued on Mar. 15, 2016 as U.S. Pat. No. 9,282,966, which is a continuation-in-part application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 13/369,601, entitled ROBOTICALLY-CONTROLLED SURGICAL END EFFECTOR SYSTEM, filed on Feb. 9, 2012, which issued on Jul. 22, 2014 as U.S. Pat. No. 8,783,541, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 13/118,246, entitled ROBOTICALLY-DRIVEN SURGICAL INSTRUMENT WITH E-BEAM DRIVER, filed on May 27, 2011, which issued on Jun. 23, 2015 as U.S. Pat. No. 9,060,770, which is a continuation-in-part application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 11/538,154, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed on Oct. 3, 2006, now U.S. Patent Application Publication No. 2007/0084897, the entire disclosures of which are hereby incorporated by reference herein. This application is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 16/384,011, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Apr. 15, 2019, now U.S. Patent Application Publication No. 2019/0307452, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 15/679,300, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Aug. 17, 2017, which issued on May 21, 2019 as U.S. Pat. No. 10,292,707, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/850,030, entitled ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE E-BEAM FIRING MECHANISM, filed Sep. 10, 2015, which issued on Aug. 22, 2017 as U.S. Pat. No. 9,737,303, which is a continuation application under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/521,748, entitled STAPLE CARTRIDGE, filed Oct. 23, 2014, which issued on Dec. 6, 2016 as U.S. Pat. No. 9,510,830, which is a continuation application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 14/175,148, entitled SURGICAL STAPLING INSTRUMENT, filed Feb. 7, 2014, which issued on Mar. 15, 2016 as U.S. Pat. No. 9,282,966, which is a continuation-in-part application claiming priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 11/141,753, entitled SURGICAL STAPLING INSTRUMENT HAVING AN ELECTROACTIVE POLYMER ACTUATED MEDICAL SUBSTANCE DISPENSER, filed on Jun. 1, 2005, which issued on Dec. 9, 2014 as U.S. Pat. No. 8,905,977, which claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/591,694, entitled SURGICAL INSTRUMENT INCORPORATING AN ELECTRICALLY ACTUATED ARTICULATION MECHANISM, filed on Jul. 28, 2004, the entire disclosures of which are hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates in general to surgical instruments that are suitable for endoscopically inserting an end effector that is actuated by a longitudinally driven firing member, and more particularly a surgical stapling and severing instrument that has an articulating shaft.

BACKGROUND OF THE INVENTION

Endoscopic surgical instruments are often preferred over traditional open surgical devices since a smaller incision tends to reduce the post-operative recovery time and complications. Consequently, significant development has gone into a range of endoscopic surgical instruments that are suitable for precise placement of a distal end effector at a desired surgical site through a cannula of a trocar. These distal end effectors engage the tissue in a number of ways to achieve a diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter, staplers, clip applier, access device, drug/gene therapy delivery device, and energy device using ultrasound, RF, laser, etc.).

Positioning the end effector is constrained by the trocar. Generally these endoscopic surgical instruments include a long shaft between the end effector and a handle portion manipulated by the clinician. This long shaft enables insertion to a desired depth and rotation about the longitudinal axis of the shaft, thereby positioning the end effector to a degree. With judicious placement of the trocar and use of graspers, for instance, through another trocar, often this amount of positioning is sufficient. Surgical stapling and severing instruments, such as described in U.S. Pat. No. 5,465,895, are an example of an endoscopic surgical instrument that successfully positions an end effector by insertion and rotation.

More recently, U.S. patent application Ser. No. 10/443,617, entitled SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM, filed on May 20, 2003, now U.S. Pat. No. 6,978,921, which is incorporated by reference in its entirety, describes an improved “E-beam” firing bar for severing tissue and actuating staples. Some of the additional advantages include affirmatively spacing the jaws of the end effector, or more specifically a staple applying assembly, even if slightly too much or too little tissue is clamped for optimal staple formation. Moreover, the E-beam firing bar engages the end effector and staple cartridge in a way that enables several beneficial lockouts to be incorporated.

Depending upon the nature of the operation, it may be desirable to further adjust the positioning of the end effector of an endoscopic surgical instrument. In particular, it is often desirable to orient the end effector at an axis transverse to the longitudinal axis of the shaft of the instrument. The transverse movement of the end effector relative to the instrument shaft is conventionally referred to as “articulation”. This is typically accomplished by a pivot (or articulation) joint being placed in the extended shaft just proximal to the staple applying assembly. This allows the surgeon to articulate the staple applying assembly remotely to either side for better surgical placement of the staple lines and easier tissue manipulation and orientation. This articulated positioning permits the clinician to more easily engage tissue in some instances, such as behind an organ. In addition, articulated positioning advantageously allows an endoscope to be positioned behind the end effector without being blocked by the instrument shaft.

Approaches to articulating a surgical stapling and severing instrument tend to be complicated by integrating control of the articulation along with the control of closing the end effector to clamp tissue and fire the end effector (i.e., stapling and severing) within the small diameter constraints of an endoscopic instrument. Generally, the three control motions are all transferred through the shaft as longitudinal translations. For instance, U.S. Pat. No. 5,673,840 discloses an accordion-like articulation mechanism (“flex-neck”) that is articulated by selectively drawing back one of two connecting rods through the implement shaft, each rod offset respectively on opposite sides of the shaft centerline. The connecting rods ratchet through a series of discrete positions.

Another example of longitudinal control of an articulation mechanism is U.S. Pat. No. 5,865,361 that includes an articulation link offset from a camming pivot such that pushing or pulling longitudinal translation of the articulation link effects articulation to a respective side. Similarly, U.S. Pat. No. 5,797,537 discloses a similar rod passing through the shaft to effect articulation.

In commonly-owned U.S. patent application Ser. No. 10/615,973, entitled SURGICAL INSTRUMENT INCORPORATING AN ARTICULATION MECHANISM HAVING ROTATION ABOUT THE LONGITUDINAL AXIS, now U.S. Pat. No. 7,111,769, the disclosure of which is hereby incorporated by reference in its entirety, a rotational motion is used to transfer articulation motion as an alternative to a longitudinal motion.

In the application entitled SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM, U.S. patent application Ser. No. 10/443,617, filed on May 20, 2003, now U.S. Pat. No. 6,978,921, the disclosure of which was previously incorporated by reference in its entirety, a surgical severing and stapling instrument, suitable for laparoscopic and endoscopic clinical procedures, clamps tissue within an end effector of an elongate channel pivotally opposed by an anvil. An E-beam firing bar moves distally through the clamped end effector to sever tissue and to drive staples on each side of the cut. The E-beam firing bar affirmatively spaces the anvil from the elongate channel to assure properly formed closed staples, especially when an amount of tissue is clamped that is inadequate to space the end effector. In particular, an upper pin of the firing bar longitudinally moves through an anvil slot and a channel slot is captured between a lower cap and a middle pin of the firing bar to assure a minimum spacing. While this E-beam firing bar has a number of advantages, additional features are desirable to enhance manufacturability and to minimize dimensional variations.

Consequently, a significant need exists for a surgical instrument with a firing bar that advantageously assures proper spacing between clamped jaws of an end effector and which facilitates articulation of its shaft.

In various embodiments, a staple cartridge seatable in a jaw of a surgical stapling instrument is disclosed. The staple cartridge comprises a cartridge body, staples, drivers, a sled, and a pan. The cartridge body comprises a deck, a longitudinal slot defined in the deck, a proximal end, a distal end, and longitudinal rows of staple cavities. The deck comprises a first deck portion on a first lateral side of the longitudinal slot and a second deck portion on a second lateral side of the longitudinal slot. The first deck portion and the second deck portion are unconnected at the proximal end. The longitudinal slot extends from the proximal end toward the distal end. The distal end connects the first deck portion and the second deck portion. The longitudinal rows of staple cavities are defined in the first deck portion and the second deck portion. The staples are removably stored in the staple cavities. The drivers are movable within the staple cavities. The sled is movable distally from a proximal position to a fired position during a staple firing stroke. The sled comprises ramps that engage the drivers during the staple firing stroke to eject the staples from the staple cavities. The pan is attached to the cartridge body. The pan comprises a first sidewall engaged with the cartridge body, a second sidewall engaged with the cartridge body, and a distal connector connecting the first sidewall and the second sidewall. The first sidewall comprises a first proximal end and a first top edge. The first sidewall defines a first through hole discrete from the first top edge. The second sidewall comprises a second proximal end and a second top edge. The second sidewall defines a second through hole discrete from the second top edge. A pan slot is defined between the first sidewall and the second sidewall such that the first proximal end is not connected to the second proximal end. The pan slot is aligned with the longitudinal slot.

In various embodiments, a staple cartridge seatable in a jaw of a surgical stapling instrument is disclosed. The staple cartridge comprises a cartridge body, staples, drivers, a sled, and a pan. The cartridge body comprises a first lateral body portion, a second lateral body portion, a longitudinal slot extending between the first lateral body portion and the second lateral body portion, a proximal end, a distal end, and longitudinal rows of staple cavities defined in the first lateral body portion and the second lateral body portion. The first lateral body portion and the second lateral body portion are unconnected at the proximal end. The longitudinal slot extends from the proximal end toward the distal end. The distal end connects the first lateral body portion and the second lateral body portion. The staples are removably stored in the staple cavities. The drivers are movable within the staple cavities. The sled is movable distally from a proximal position to a fired position during a staple firing stroke. The sled comprises ramps that engage the drivers during the staple firing stroke to eject the staples from the staple cavities. The pan is attached to the cartridge body. The pan comprises a first bottom portion extending under the first lateral body portion, a second bottom portion extending under the second lateral body portion, a pan slot defined between the first bottom portion and the second bottom portion, a first sidewall extending from the first bottom portion, a second sidewall extending from the second bottom portion, and a distal connector connecting the first bottom portion and the second bottom portion. The pan slot is aligned with the longitudinal slot. The first sidewall is engaged with the first lateral body portion. The first side wall comprises a first top edge. The first sidewall defines a first through hole discrete from the first top edge. The second side wall comprises a second top edge. The second sidewall defines a second through hole discrete from the second top edge. The second sidewall is engaged with the second lateral body portion.

In various embodiments, a replaceable staple cartridge comprising a cartridge body, staples, drivers, a sled, and a pan is disclosed. The cartridge body comprises a distal end, a proximal end, a deck, a longitudinal slot, and longitudinal rows of staple cavities. The deck comprises a first portion and a second portion. The first portion and the second portion are connected at the distal end. The longitudinal slot is defined in the deck between the first portion and the second portion. The longitudinal slot forms a gap in the deck at the proximal end. The longitudinal rows of staple cavities are defined in the first portion and the second portion. The staples are removably stored in the staple cavities. The drivers are movable within the staple cavities. The pan is attached to the cartridge body. The pan and the cartridge body form a unitary component installable in a cartridge jaw. The pan comprises a pan distal end, a first side, a second side, and a pan slot. The first side comprises a first proximal end. The second side comprises a second proximal end. The first side and the second side are connected at the pan distal end. The pan slot forms a gap between the first proximal end and the second proximal end. The pan slot is aligned with the longitudinal slot.

In various embodiments, a replaceable staple cartridge comprising a cartridge body, staples, drivers, a sled, and a pan is disclosed. The cartridge body comprises a distal end, a proximal end, a deck, a longitudinal slot, and longitudinal rows of staple cavities. The deck comprises a first portion and a second portion. The first portion and the second portion are connected at the distal end. The longitudinal slot is defined in the deck between the first portion and the second portion. The longitudinal slot forms a gap in the deck at the proximal end. The longitudinal rows of staple cavities are defined in the first portion and the second portion. The staples are removably stored in the staple cavities. The drivers are movable within the staple cavities. The pan is attached to the cartridge body. The pan comprises a pan distal end, a first side, a second side, a pan slot, and an arm. The first side comprises a first proximal end. The second side comprises a second proximal end. The first side and the second side are connected at the pan distal end. The pan slot forms a gap between the first proximal end and the second proximal end. The pan slot is aligned with the longitudinal slot. The arm extends into an opening in the cartridge body.

In various embodiments, a replaceable staple cartridge comprising a cartridge body, staples, drivers, a sled, and a pan is disclosed. The cartridge body comprises a distal end, a proximal end, a deck, a longitudinal slot, and longitudinal rows of staple cavities. The deck comprises a first portion and a second portion. The first portion and the second portion are connected at the distal end. The longitudinal slot is defined in the deck between the first portion and the second portion. The longitudinal slot forms a gap in the deck at the proximal end. The longitudinal rows of staple cavities are defined in the first portion and the second portion. The staples are removably stored in the staple cavities. The drivers are movable within the staple cavities. The pan is attached to the cartridge body. The pan comprises a pan proximal end, a pan distal end, a first side, a second side, and a pan slot. The first side comprises a first proximal end. The second side comprises a second proximal end. The first side and the second side are connected at the pan distal end. The pan slot forms a gap between the first proximal end and the second proximal end. The pan slot is aligned with the longitudinal slot. The pan slot comprises a proximal-most portion extending from the pan proximal end and comprising a first width. The pan slot further comprises a distal portion comprising a second width. The first width is greater than the second width.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.

FIG. 1 is a perspective view of an endoscopic surgical stapling instrument for surgical stapling and severing in an open, unarticulated state.

FIG. 2 is a left, front perspective view of an open staple applying assembly of the surgical stapling instrument of FIG. 1 with a right half portion of a replaceable staple cartridge included in a staple channel.

FIG. 3 is an exploded perspective view of the staple applying assembly of FIG. 2 with a complete replaceable staple cartridge and an alternative nonarticulating shaft configuration.

FIG. 4 is a perspective view of a two-piece knife and firing bar (“E-beam”) of the staple applying assembly of FIG. 2 .

FIG. 5 is a perspective view of a wedge sled of a staple cartridge of the staple applying assembly of FIG. 1 .

FIG. 6 is a left side view in elevation taken in longitudinal cross section along a centerline line 6-6 of the staple applying assembly of FIG. 2 .

FIG. 7 is a perspective view of the open staple applying assembly of FIG. 2 without the replaceable staple cartridge, a portion of the staple channel proximate to a middle pin of two-piece knife and firing bar, and without a distal portion of a staple channel.

FIG. 8 is a front view in elevation taken in cross section along line 8-8 of the staple applying assembly of FIG. 2 depicting internal staple drivers of the staple cartridge and portions of the two-piece knife and firing bar.

FIG. 9 is a left side view in elevation taken generally along the longitudinal axis of line 6-6 of a closed staple applying assembly of FIG. 2 to include center contact points between the two-piece knife and wedge sled but also laterally offset to show staples and staple drivers within the staple cartridge.

FIG. 10 is a left side detail view in elevation of the staple applying assembly of FIG. 9 with the two-piece knife retracted slightly more as typical for staple cartridge replacement.

FIG. 11 is a left side detail view in elevation of the staple applying assembly of FIG. 10 with the two-piece knife beginning to fire, corresponding to the configuration depicted in FIG. 9 .

FIG. 12 is a left side cross-sectional view in elevation of the closed staple applying assembly of FIG. 9 after the two-piece knife and firing bar has distally fired.

FIG. 13 is a left side cross-sectional view in elevation of the closed staple applying assembly of FIG. 12 after firing of the staple cartridge and retraction of the two-piece knife.

FIG. 14 is a left side cross-sectional detail view in elevation of the staple applying assembly of FIG. 13 with the two-piece knife allowed to drop into a lockout position.

FIG. 15 is a top view in section taken along lines 15-15 of an articulation joint (flex neck) of the surgical stapling instrument of FIG. 1 .

FIG. 16 is a front view in elevation taken in vertical cross section along lines 16-16 of the articulation joint of FIG. 15 , showing electroactive polymer (EAP) plate articulation actuators and EAP support plates for a firing bar.

FIG. 17 is a top view in section along lines 15-15 of the articulation joint of FIG. 16 after articulation.

FIG. 18 is a perspective view of the articulation joint of FIG. 15 .

DETAILED DESCRIPTION OF THE INVENTION

The entire disclosure of U.S. patent application Ser. No. 11/082,495, entitled SURGICAL INSTRUMENT INCORPORATING AN ELECTRICALLY ACTUATED ARTICULATION MECHANISM, filed on Mar. 17, 2005, now U.S. Pat. No. 7,506,790, is incorporated herein by reference. The entire disclosure of U.S. Pat. No. 6,667,825, entitled STABLE CONJUGATED POLYMER ELECTROCHROMIC DEVICES INCORPORATING IONIC LIQUIDS, issued on Jan. 3, 2002, is incorporated herein by reference. The entire disclosure of U.S. patent application Ser. No. 11/061,908, entitled SURGICAL INSTRUMENT INCORPORATING A FLUID TRANSFER CONTROLLED ARTICULATION MECHANISM, filed on Feb. 18, 2005, now U.S. Pat. No. 7,559,450, is incorporated herein by reference.

In FIGS. 1-3 , a surgical stapling instrument 10 has at its distal end an end effector, depicted as a staple applying assembly 12, spaced apart from a handle 14 (FIG. 2 ) by an elongate shaft 16. The staple applying assembly 12 includes a staple channel 18 for receiving a replaceable staple cartridge 20. Pivotally attached to the staple channel 18 is an anvil 22 that clamps tissue to the staple cartridge 20 and serves to deform staples 23 (FIG. 3 ) driven up from staple holes 24 in the staple cartridge 20 against staple forming recesses 26 (FIG. 6 ) in an anvil undersurface 28 into a closed shape. When the staple applying assembly 12 is closed, its cross sectional area, as well as the elongate shaft 16 are suitable for insertion through a small surgical opening, such as through a cannula of a trocar (not shown).

With particular reference to FIG. 1 , correct placement and orientation of the staple applying assembly 12 is facilitated by controls on the handle 14. In particular, a rotation knob 30 causes rotation of the shaft 16 about its longitudinal axis, and hence rotation of the staple applying assembly 12. Additional positioning is enabled at an articulation joint 32 in the shaft 16 that pivots the staple applying assembly 12 in an arc from the longitudinal axis of the shaft 16, thereby allowing placement behind an organ or allowing other instruments such as an endoscope (not shown) to be oriented behind the staple applying assembly 12. This articulation is advantageously effected by an articulation control switch 34 on the handle 14 that transmits an electrical signal to the articulation joint 32 to an Electroactive Polymer (EAP) actuator 36, powered by an EAP controller and power supply 38 contained within the handle 14.

Once positioned with tissue in the staple applying assembly 12, a surgeon closes the anvil 22 by drawing a closure trigger 40 proximally toward a pistol grip 42. Once clamped thus, the surgeon may grasp a more distally presented firing trigger 44, drawing it back to effect firing of the staple applying assembly 12, which in some applications is achieved in one single firing stroke and in other applications by multiple firing strokes. Firing accomplishes simultaneously stapling of at least two rows of staples while severing the tissue therebetween.

Retraction of the firing components may be automatically initiated upon full travel. Alternatively, a retraction lever 46 may be drawn aft to effect retraction. With the firing components retracted, the staple applying assembly 12 may be unclamped and opened by the surgeon slightly drawing the closure trigger 40 aft toward the pistol grip 42 and depressing a closure release button 48 and then releasing the closure trigger 40, thereby releasing the two stapled ends of severed tissue from the staple applying assembly 12.

Staple Applying Assembly

While an articulation joint 32 is depicted in FIG. 1 , for clarity and as an alternative application, the surgical stapling instrument 10 of FIGS. 2-14 omit an articulation joint 32. It should be appreciated, however, that aspects of the present invention have particular advantages for articulation as described below with regard to FIGS. 15-18 .

In FIGS. 1-3 , the staple applying assembly 12 accomplishes the functions of clamping onto tissue, driving staples and severing tissue by two distinct motions transferred longitudinally down the shaft 16 over a shaft frame 70. This shaft frame 70 is proximally attached to the handle 14 and coupled for rotation with the rotation knob 30. An illustrative multi-stroke handle 14 for the surgical stapling and severing instrument 10 of FIG. 1 is described in greater detail in the commonly-owned U.S. patent application Ser. No. 10/674,026, entitled SURGICAL STAPLING INSTRUMENT INCORPORATING A MULTISTROKE FIRING POSITION INDICATOR AND RETRACTION MECHANISM, now U.S. Pat. No. 7,364,061, the disclosure of which is hereby incorporated by reference in its entirety, with additional features and variation as described herein. While a multi-stroke handle 14 advantageously supports applications with high firing forces over a long distance, applications consistent with the present invention may incorporate a single firing stroke, such as described in commonly-owned U.S. patent application Ser. No. 10/441,632, entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, now U.S. Pat. No. 7,000,818, the disclosure of which is hereby incorporated by reference in its entirety.

With particular reference to FIG. 3 , the distal end of the shaft frame 70 is attached to the staple channel 18. The anvil 22 has a proximal pivoting end 72 that is pivotally received within a proximal end 74 of the staple channel 18, just distal to its engagement to the shaft frame 70. The pivoting end 72 of the anvil 22 includes a closure feature 76 proximate but distal to its pivotal attachment with the staple channel 18. Thus, a closure tube 78, whose distal end includes a horseshoe aperture 80 that engages this closure feature 76, selectively imparts an opening motion to the anvil 22 during proximal longitudinal motion and a closing motion to the anvil 22 during distal longitudinal motion of the closure tube 78 sliding over the shaft frame 70 in response to the closure trigger 40.

The shaft frame 70 encompasses and guides a firing motion from the handle 14 through a longitudinally reciprocating, two-piece knife and firing bar 90. In particular, the shaft frame 70 includes a longitudinal firing bar slot 92 that receives a proximal portion of the two-piece knife and firing bar 90, specifically a laminate tapered firing bar 94. It should be appreciated that the laminated tapered firing bar 94 may be substituted with a solid firing bar or of other materials in applications not intended to pass through an articulation joint, such as depicted in FIGS. 2-14 .

An E-beam 102 is the distal portion of the two-piece knife and firing bar 90, which facilitates separate closure and firing as well as spacing of the anvil 22 from the elongate staple channel 18 during firing. With particular reference to FIGS. 3-4 , in addition to any attachment treatment such as brazing or an adhesive, the knife and firing bar 90 are formed of a female vertical attachment aperture 104 proximally formed in the E-beam 102 that receives a corresponding male attachment member 106 distally presented by the laminated tapered firing bar 94, allowing each portion to be formed of a selected material and process suitable for their disparate functions (e.g., strength, flexibility, friction). The E-beam 102 may be advantageously formed of a material having suitable material properties for forming a pair of top pins 110, a pair of middle pins 112 and a bottom pin or foot 114, as well as being able to acquire a sharp cutting edge 116. In addition, integrally formed and proximally projecting top guide 118 and middle guide 120 bracketing each vertical end of the cutting edge 116 further define a tissue staging area 122 assisting in guiding tissue to the sharp cutting edge 116 prior to being severed. The middle guide 120 also serves to engage and fire the staple applying apparatus 12 by abutting a stepped central member 124 of a wedge sled 126 (FIG. 5 ) that effects staple formation by the staple applying assembly 12, as described in greater detail below.

Forming these features (e.g., top pins 110, middle pins 112, and bottom foot 114) integrally with the E-beam 102 facilitates manufacturing at tighter tolerances relative to one another as compared to being assembled from a plurality of parts, ensuring desired operation during firing and/or effective interaction with various lockout features of the staple applying assembly 12.

In FIGS. 6-7 , the surgical stapling instrument 10 is shown open, with the E-beam 102 fully retracted. During assembly, the lower foot 114 of the E-beam 102 is dropped through a widened hole 130 in the staple channel 18 and the E-beam 102 is then advanced such that the E-beam 102 slides distally along a lower track 132 formed in the staple channel 18. In particular, the lower track 132 includes a narrow slot 133 that opens up as a widened slot 134 on an undersurface of the staple channel 18 to form an inverted T-shape in lateral cross section, as depicted particularly in FIGS. 7 and 8 , which communicates with the widened hole 130. Once assembled, the components proximally coupled to the laminate tapered firing bar 94 do not allow the lower foot 114 to proximally travel again to the widened hole 130 to permit disengagement.

In FIG. 9 , the laminate tapered firing bar 94 facilitates insertion of the staple applying assembly 12 through a trocar. In particular, a more distal, downward projection 136 raises the E-beam 102 when fully retracted. This is accomplished by placement of the downward projection 136 at a point where it cams upwardly on a proximal edge of the widened hole 130 in the staple channel 18.

In FIG. 10 , the laminate tapered firing bar 94 also enhances operation of certain lockout features that may be incorporated into the staple channel 18 by including a more proximal upward projection 138 that is urged downwardly by the shaft frame 70 during an initial portion of the firing travel. In particular, a lateral bar 140 is defined between a pair of square apertures 142 in the shaft frame 70 (FIG. 3 ). A clip spring 144 that encompasses the lateral bar 140 downwardly urges a portion of the laminate tapered firing bar 94 projecting distally out of the longitudinal firing bar slot 92, which ensures certain advantageous lockout features are engaged when appropriate. This urging is more pronounced or confined solely to that portion of the firing travel when the upward projection 138 contacts the clip spring 144.

In FIGS. 6-7 , the E-beam 102 is retracted with the top pins 110 thereof residing within an anvil pocket 150 near the pivoting proximal end of the anvil 22. A downwardly open vertical anvil slot 152 (FIG. 2 ) laterally widens in the anvil 22 into an anvil internal track 154 that captures the top pins 110 of the E-beam 102 as they distally advance during firing, as depicted in FIGS. 9-10 , affirmatively spacing the anvil 22 from the staple channel 18. Thus, with the E-beam 102 retracted, the surgeon is able to repeatably open and close the staple applying assembly 12 until satisfied with the placement and orientation of tissue captured therein for stapling and severing, yet the E-beam 102 assists in proper positioning of tissue even for a staple applying assembly 12 of reduced diameter and correspondingly reduced rigidity.

In FIGS. 2-3, 5-6, 8-14 , the staple applying assembly 12 is shown with the replaceable staple cartridge 20 that includes the wedge sled 126. Longitudinally aligned and parallel plurality of downwardly open wedge slots 202 (FIG. 8 ) receive respective wedges 204 integral to the wedge sled 126. In FIGS. 8-10 , the wedge sled 126 thus cams upwardly a plurality of staple drivers 206 that are vertically slidable within staple driver recesses 208. In this illustrative version, each staple driver 206 includes two vertical prongs, each translating upwardly into a respective staple hole 210 to upwardly force out and deform a staple 23 resting thereupon against a staple forming surface 214 (FIG. 10 ) of the anvil 22. A central firing recess 216 (FIG. 3 ) defined within the staple cartridge 20 proximate to the staple channel 18 allows the passage of the bottom, horizontal portion 218 (FIG. 5 ) of the wedge sled 126 as well as the middle pins 112 of the E-beam 102. Specifically, a staple cartridge tray 220 (FIGS. 3, 8 ) attaches to and underlies a polymer staple cartridge body 222 that has the staple driver recesses 208, staple holes 210, and central firing recess 216 formed therein. As staples 23 are thus formed to either side, the sharp cutting edge 116 enters a vertical through slot 230 passing through the longitudinal axis of the staple cartridge 20, excepting only a most distal end thereof.

Firing the staple applying assembly 12 begins as depicted in FIG. 10 with the two-piece knife and firing bar 90 proximally drawn until the downward projection 136 cams the middle guide 120 on the E-beam 102 upward and aft, allowing a new staple cartridge 20 to be inserted into the staple channel 18 when the anvil 22 is open as depicted in FIGS. 2, 6 .

In FIG. 11 , the two-piece knife and firing bar 90 has been distally advanced a small distance, allowing the downward projection 136 to drop into the widened hole 130 of the lower track 132 under the urging of the clip spring 144 against the upward projection 138 of the laminate tapered firing bar 94. The middle guide 120 prevents further downward rotation by resting upon the stepped central member 124 of the wedge sled 126, thus maintaining the middle pin 112 of the E-beam within the central firing recess 216.

In FIG. 12 , the two-piece knife and firing bar 90 has been distally fired, advancing the wedge sled 126 to cause formation of staples 23 while severing tissue 242 clamped between the anvil 22 and staple cartridge 20 with the sharp cutting edge 116. Thereafter, in FIG. 13 , the two-piece knife and firing bar 90 is retracted, leaving the wedge sled 126 distally positioned.

In FIG. 14 , the middle pin 112 is allowed to translate down into a lockout recess 240 formed in the staple channel 18 (also see FIGS. 7, 10 ). Thus, the operator would receive a tactile indication as the middle pin 112 encounters the distal edge of the lockout recess 240 when the wedge sled 126 (not shown in FIG. 14 ) is not proximally positioned (i.e., missing staple cartridge 20 or spent staple cartridge 20).

In FIG. 1 , an articulation joint 32 is depicted that advantageously benefits from the flexible strength of the two-piece knife and firing bar 90. In FIGS. 15-18 , the articulation joint 32 is depicted as a flex neck joint 300 formed by vertebral column body 302 having laterally symmetric pairs of arcing recesses 304 that allow articulation in an articulation plane. It is generally known to simultaneously compress and expand respective lateral sides 306, 308 by selective movement of control rods (not shown) that longitudinally pass through the respective lateral sides 306, 308. Depicted, however, are EAP plate actuators 310, 312, each capable of powered deflection to one or both lateral directions.

A central passage 320 (FIG. 16 ) defined longitudinally through the vertebral column body 302 receives a pair of support plates 322, 324 that prevent buckling and binding of the laminate tapered firing bar 94. In the illustrative version, each support plate 322, 324 has a proximal fixed end 326 (FIG. 15 ) and a sliding end 328 to accommodate changes in radial distance during articulation. Having a firing bar 94 of a thinner thickness is thus supported.

While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications may readily appear to those skilled in the art.

For example, while there are a number of advantages to having a wedge sled integral to a staple cartridge, in some applications consistent with aspects of the present invention, the wedge sled may be integral instead to an E-beam. For instance, an entire end effector may be replaceable rather than just the staple cartridge. 

What is claimed is:
 1. A staple cartridge seatable in a jaw of a surgical stapling instrument, said staple cartridge comprising: a cartridge body, comprising: a deck; a longitudinal slot defined in said deck, wherein said deck comprises a first deck portion on a first lateral side of said longitudinal slot and a second deck portion on a second lateral side of said longitudinal slot; a proximal end, wherein said first deck portion and said second deck portion are unconnected at said proximal end; a distal end, wherein said longitudinal slot extends from said proximal end toward said distal end, and wherein said distal end connects said first deck portion and said second deck portion, and; longitudinal rows of staple cavities defined in said first deck portion and said second deck portion; staples removably stored in said staple cavities; drivers movable within said staple cavities; a sled movable distally from a proximal position to a fired position during a staple firing stroke, wherein said sled comprises ramps that engage said drivers during said staple firing stroke to eject said staples from said staple cavities; and a pan attached to said cartridge body, comprising: a first sidewall engaged with said cartridge body, wherein said first sidewall comprises a first proximal end and a first top edge, wherein said first sidewall defines a first through hole discrete from said first top edge; a second sidewall engaged with said cartridge body, wherein said second sidewall comprises a second proximal end and a second top edge, wherein said second sidewall defines a second through hole discrete from said second top edge, wherein a pan slot is defined between said first sidewall and said second sidewall such that said first proximal end is not connected to said second proximal end, and wherein said pan slot is aligned with said longitudinal slot; and a distal connector connecting said first sidewall and said second sidewall.
 2. The staple cartridge of Claim 1, wherein said distal end of said cartridge body protrudes distally from said distal connector of said pan.
 3. A staple cartridge seatable in a jaw of a surgical stapling instrument, said staple cartridge comprising: a cartridge body, comprising: a first lateral body portion; a second lateral body portion; a longitudinal slot extending between said first lateral body portion and said second lateral body portion; a proximal end, wherein said first lateral body portion and said second lateral body portion are unconnected at said proximal end; a distal end, wherein said longitudinal slot extends from said proximal end toward said distal end, and wherein said distal end connects said first lateral body portion and said second lateral body portion, and; longitudinal rows of staple cavities defined in said first lateral body portion and said second lateral body portion; staples removably stored in said staple cavities; drivers movable within said staple cavities; a sled movable distally from a proximal position to a fired position during a staple firing stroke, wherein said sled comprises ramps that engage said drivers during said staple firing stroke to eject said staples from said staple cavities; and a pan attached to said cartridge body, comprising: a first bottom portion extending under said first lateral body portion; a second bottom portion extending under said second lateral body portion; a pan slot defined between said first bottom portion and said second bottom portion, wherein said pan slot is aligned with said longitudinal slot; a first sidewall extending from said first bottom portion, wherein said first sidewall is engaged with said first lateral body portion, wherein said first sidewall comprises a first top edge, and wherein said first sidewall defines a first through hole discrete from said first top edge; a second sidewall extending from said second bottom portion, wherein said second sidewall comprises a second top edge, and wherein said second sidewall defines a second through hole discrete from said second top edge, wherein said second sidewall is engaged with said second lateral body portion; and a distal connector connecting said first bottom portion and said second bottom portion.
 4. The staple cartridge of Claim 3, wherein said distal end of said cartridge body protrudes distally from said distal connector of said pan.
 5. A replaceable staple cartridge, comprising: a cartridge body, comprising: a distal end; a proximal end; a deck comprising a first portion and a second portion, wherein said first portion and said second portion are connected at said distal end; a longitudinal slot defined in said deck between said first portion and said second portion, wherein said longitudinal slot forms a gap in said deck at said proximal end; and longitudinal rows of staple cavities defined in said first portion and said second portion; staples removably stored in said staple cavities; drivers movable within said staple cavities; a sled; and a pan attached to said cartridge body, wherein said pan and said cartridge body form a unitary component installable in a cartridge jaw, said pan comprising: a pan distal end; a first side comprising a first proximal end; a second side comprising a second proximal end, wherein said first side and said second side are connected at said pan distal end; and a pan slot forming a gap between said first proximal end and said second proximal end, wherein said pan slot is aligned with said longitudinal slot.
 6. The replaceable staple cartridge of claim 5, wherein said cartridge body further comprises a first lateral side and a second lateral side, and wherein said pan further comprises: a first bottom wall extending under said first portion; a first upright wall extending along said first lateral side, wherein said first upright wall comprises a first top edge, wherein a first array of through holes are defined in said first upright wall, wherein each said through hole of said first array of through holes is discrete from said first top edge, wherein said first upright wall comprises a first notch positioned intermediate adjacent through holes in said first array of through holes, and wherein said first notch is contiguous with said first top edge; a second bottom wall extending under said second portion; a second upright wall extending along said second lateral side, wherein said first upright wall comprises a second top edge, wherein a second array of through holes are defined in said second upright wall, wherein each said through hole of said second array of through holes is discrete from said second top edge, wherein said second upright wall comprises a second notch positioned intermediate adjacent through holes in said second array of through holes, and wherein said second notch is contiguous with said second top edge; a first arm comprising a first hook, wherein said first arm comprises said first proximal end; and a second arm comprising a second hook, wherein said second arm comprises said second proximal end.
 7. The replaceable staple cartridge of claim 6, wherein said pan further comprises a pan proximal end, and wherein said pan slot comprises: a proximal-most portion extending from said pan proximal end and comprising a first width; and a distal portion comprising a second width, wherein said first width is greater than said second width.
 8. The replaceable staple cartridge of claim 7, wherein said sled comprises distal-facing ramps positioned to engage said drivers during a staple firing stroke.
 9. The replaceable staple cartridge of claim 5, wherein said first side further comprises a first top edge, wherein a first hole is defined in said first side, and wherein a portion of said first side extends longitudinally between said first top edge and said first hole.
 10. The replaceable staple cartridge of claim 9, wherein said second side further comprises a second top edge, wherein a second hole is defined in said second side, and wherein a portion of said second side extends longitudinally between said second top edge and said second hole.
 11. The replaceable staple cartridge of claim 10, wherein said first side further comprises a first notch contiguous with said first top edge, and wherein said second side further comprises a second notch contiguous with said second top edge.
 12. The replaceable staple cartridge of claim 11, wherein said first hole is noncontiguous with said first top edge, and wherein said second hole is noncontiguous with said second top edge.
 13. The replaceable staple cartridge of claim 5, wherein said sled comprises distal-facing ramps positioned to engage said drivers during a staple firing stroke.
 14. The replaceable staple cartridge of claim 5, wherein said cartridge body further comprises a first lateral side and a second lateral side, and wherein said pan further comprises: a first bottom wall extending under said first portion; a first upright wall extending along said first lateral side; a second bottom wall extending under said second portion; and a second upright wall extending along said second lateral side.
 15. The replaceable staple cartridge of claim 14, wherein a first through hole is defined through said first upright wall, and wherein a second through hole is defined through said second upright wall.
 16. The replaceable staple cartridge of claim 15, wherein said first upright wall comprises a top edge and a plurality of through holes spaced apart along said first upright wall and discrete from said top edge, wherein said plurality of through holes comprises said first through hole.
 17. The replaceable staple cartridge of claim 16, wherein said first upright wall further comprises a notch contiguous with said top edge and positioned intermediate adjacent through holes of said plurality of through holes.
 18. A replaceable staple cartridge, comprising: a cartridge body, comprising: a distal end; a proximal end; a deck comprising a first portion and a second portion, wherein said first portion and said second portion are connected at said distal end; a longitudinal slot defined in said deck between said first portion and said second portion, wherein said longitudinal slot forms a gap in said deck at said proximal end; and longitudinal rows of staple cavities defined in said first portion and said second portion; staples removably stored in said staple cavities; drivers movable within said staple cavities; a sled; and a pan attached to said cartridge body, comprising: a pan distal end; a first side comprising a first proximal end; a second side comprising a second proximal end, wherein said first side and said second side are connected at said pan distal end; a pan slot forming a gap between said first proximal end and said second proximal end, wherein said pan slot is aligned with said longitudinal slot; and an arm extending into an opening in said cartridge body.
 19. The replaceable staple cartridge of claim 18, wherein said arm further comprises a hook extending around a portion of said cartridge body.
 20. The replaceable staple cartridge of claim 18, wherein said arm further comprises said first proximal end.
 21. A replaceable staple cartridge, comprising: a cartridge body, comprising: a distal end; a proximal end; a deck comprising a first portion and a second portion, wherein said first portion and said second portion are connected at said distal end; a longitudinal slot defined in said deck between said first portion and said second portion, wherein said longitudinal slot forms a gap in said deck at said proximal end; and longitudinal rows of staple cavities defined in said first portion and said second portion; staples removably stored in said staple cavities; drivers movable within said staple cavities; a sled; and a pan attached to said cartridge body, comprising: a pan proximal end; a pan distal end; a first side comprising a first proximal end; a second side comprising a second proximal end, wherein said first side and said second side are connected at said pan distal end; and a pan slot forming a gap between said first proximal end and said second proximal end, wherein said pan slot is aligned with said longitudinal slot, and wherein said pan slot comprises: a proximal-most portion extending from said pan proximal end and comprising a first width; and a distal portion comprising a second width, wherein said first width is greater than said second width. 